Moulds with sealable column pieces and methods for manufacturing products with these moulds

Abstract

Molds and a method of using the molds to manufacture a product are provided. The molds include a first mold part having a first wall from which a first column member projects, having first side walls and a first distal end, and a second mold part having a second wall from which a second column member projects, having second side walls and a second distal end. The first and second mold parts are configured to releasably mate together to define a mold cavity therebetween such that the first and second column members releasably mate together, with the first distal end being received within a cavity of the second distal end to form a seal therebetween. The mold cavity is configured to receive a product material and form the product therefrom. The first side walls and the second side walls are configured to define a passageway in the product.

Description

introduction

[0001] The technical field relates generally to molds, and more particularly to a mold having pillars within a mold cavity to form passageways in a product formed in the mold cavity, the pillars comprising a pair of pillar pieces that are mated (bringing together two matching mating surfaces) to form a seal therebetween.

[0002] Molds used in molding processes to manufacture products may have one or more features within the mold cavity designed to create passageways in the products. For example, molds used to manufacture foam cushions may include one or more pillars designed to create vent holes in the foam cushions. In some molds, the pillars each comprise a pair of column pieces with flat distal ends configured to touch each other upon mold closing (e.g., "kiss-off"). During the molding process, foam enters between the column pieces, resulting in spalling. In some cases, this spalling must be removed in subsequent processing steps to allow airflow through the vent holes.

[0003] Accordingly, it is desirable to provide molds and methods for manufacturing products with shapes that prevent or reduce the likelihood of chipping. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing introduction. Description

[0004] A mold is provided for manufacturing a product. In one example, the mold includes a first mold part having a first wall with a first column member protruding from the first wall, the first column member including first side walls and a first distal end, and a second mold part having a second wall with a second column member protruding from the second wall, the second column member including second side walls and a second distal end including an opening to a cavity defined by interior walls of the second column member.

[0005] The first mold part and the second mold part are configured to releasably mate with the first wall and the second wall and form a mold cavity therebetween. The first column member and the second column member are configured to releasably mate with each other while the first mold part and the second mold part mate such that the first distal end of the first column member is received within the cavity of the second distal end of the second column member and a seal is formed between the first distal end and the second distal end. The mold cavity is configured to receive a product material and form the product therefrom. The first side walls and the second side walls are configured to define a passageway in the product.

[0006] In various examples, the first mold part and the second mold part of the mold are attached with a hinge and configured to rotate about the hinge to be mateable.

[0007] In various examples, the first side walls and the second side walls of the mold are flush, while the first column member and the second column member are fitted together.

[0008] In various examples, the first distal end of the first column member has first tapered parting line surfaces terminating with a protruding surface, the second distal end of the second column member has second tapered parting line surfaces terminating with a depressed surface, and the first parting line surfaces and the second parting line surfaces are configured to mate to form the seal between the first distal end and the second distal end.

[0009] In various examples, the first distal end has more than one protrusion and the second distal end has more than one recess, and each of the more than one recess is configured to receive a corresponding one of the more than one protrusion.

[0010] In various examples, the first column member is a first of more than one first column member of the first molding that protrudes from the first wall, and the second column member is a first of more than one second column member of the second molding that protrudes from the second wall.

[0011] In various examples, the mold includes a sealing element at at least one of the first distal end and the second distal end configured to assist in sealing between the first column member and the second column member during mating of the first column member and the second column member. In some examples, the sealing element comprises an epoxy material or a silicone material.

[0012] In various examples, the product is a seat cushion for a vehicle, the seat cushion is formed of a foam material, and the passage is a ventilation hole.

[0013] In various examples, the first column member and the second column member in combination have an overall longitudinal dimension of six millimeters or less when mated together.

[0014] A method of manufacturing a product is provided. In one example, the method comprises coupling a first mold part and a second mold part of a mold to provide a sealed mold cavity therebetween, the mold cavity being defined by a first wall of the first mold part and a second wall of the second mold part, wherein the coupling of the first mold part and the second mold part effects mating of a first column member protruding from the first wall and a second column member protruding from the second wall, wherein a first distal end of the first column member is received within a cavity in a second distal end of the second column member and a seal is formed between the first distal end and the second distal end, a product material is introduced into the mold cavity, and the product material is solidified to form a product therefrom,wherein first side walls of the first column member and second side walls of the second column member define a passage in the product.,

[0015] In various examples, the first mold part and the second mold part are attached with a hinge, and coupling the first mold part and a second mold part includes pivoting at least one of the first mold part and the second mold part about the hinge to fit them together.

[0016] In various examples, coupling the first column member and the second column member includes arranging the first side walls and the second side walls relative to each other so that they are flush while the first column member and the second column member are mated together.

[0017] In various examples, the first distal end of the first column member has first tapered parting line surfaces terminating with a protruding surface, the second distal end of the second column member has second tapered parting line surfaces terminating with a depressed surface, and coupling the first column member and the second column member comprises mating the first parting line surfaces and the second parting line surfaces to form the seal between the first distal end and the second distal end.

[0018] In various examples, the first distal end has more than one protrusion and the second distal end has more than one recess, and the method includes mating each of the first distal end and the second distal end by arranging each of the more than one protrusion with a corresponding one of the more than one recess.

[0019] In various examples, the first column member is a first of more than one first column member of the first molding that protrudes from the first wall, the second column member is a first of more than one second column member of the second molding that protrudes from the second wall, and the method includes coupling pairs of the first column members and the second column members.

[0020] In various examples, the mold includes a sealing member at at least one of the first distal end and the second distal end, and the method includes mating the first column member and the second column member such that the sealing member assists in sealing between the first column member and the second column member.

[0021] In various examples, the mold includes a sealing member at at least one of the first distal end and the second distal end, and the method includes mating the first column member and the second column member such that the sealing member reduces the likelihood of wear on the first column member and the second column member.

[0022] In various examples, the product is a seat cushion for a vehicle, the seat cushion is formed from a foam material, the passageway is a vent hole, and the method includes installing the seat cushion into the vehicle.

[0023] A mold is provided for manufacturing a product. In one example, the mold includes a first mold part having a first wall with a first column member protruding from the first wall, the first column member having first side walls and a first distal end, a second mold part having a second wall with a second column member protruding from the second wall, the second column member having second side walls and a second distal end having an opening to a cavity defined by interior walls of the second column member, the first mold part and the second mold part being configured to releasably mate with the first wall and the second wall and define a mold cavity therebetween, the first column member and the second column member being configured to releasably mate with each other while the first mold part and the second mold part are mated together,wherein the first distal end of the first column member is at least partially received within the cavity of the second distal end of the second column member, and a seal is formed between the first distal end and the second distal end, the first distal end having more than one protrusion and the second distal end having more than one recess, each of the more than one recesses being configured to receive a corresponding one of the more than one protrusions, and a sealing member on at least one of the first distal end and the second distal end configured to assist in the seal between the first column member and the second column member while the first column member and the second column member are mated together. The mold cavity is configured to receive a product material and form a product therefrom, the first sidewalls and the second sidewalls being configured,to define a passage in the product., Brief description of the drawings

[0024] The exemplary embodiments are described below in conjunction with the following drawings, wherein like numerals indicate like elements: Fig. 1 is a perspective view of a mold according to an example; Fig. 2 is a cross-sectional view of a first, unconstrained interface of column pieces of a mold according to an example; Fig. 3 is a cross-sectional view of a second, unconstrained interface of column pieces of a mold according to an example; Fig. 4 is a cross-sectional view of a third, unconstrained interface of column pieces of a mold according to an example; and Fig. 5 is a flowchart showing a method for manufacturing a product from a mold according to an example. Detailed description

[0025] The following detailed description is merely exemplary and is not intended to limit the application and use. Furthermore, there is no intention to be bound by any express or implied theory presented in the preceding introduction or the following detailed description.

[0026] First, Fig. 1 shows a non-limiting example of a mold 100. The mold 100 can be configured for use in a molding process for manufacturing various products from different materials. In particular, the mold 100 is configured to receive a deformable or viscous liquid product material within a mold cavity and solidify the product material to form a product.

[0027] Various materials may be used to form the product in the mold 100, including certain polymeric materials. In some examples, the product may be formed from a thermosetting polymer material, and the product material used in the mold 100 may be a prepolymer mixture (reactive resin, reactive material, etc.) that is poured into the mold 100 and can cure, i.e., can chemically react to create crosslinking between polymer chains and form a polymer network. The prepolymer mixture may include, for example, a resin, a curing agent or crosslinker, a filler, a catalyst, a plasticizer, a modifier (e.g., a toughener), a solvent, an inhibitor, and / or a dye or pigment. In one example, the product material is a thermosetting prepolymer mixture containing an isocyanate resin.In some examples, the chemical reaction may result in foaming of the product material, forming the product from a foam. In other examples, the product material may include a melt of a thermoplastic resin. In some examples, the mold 100 may be used in an open-pore process (e.g., open-cast foam process).

[0028] The mold 100 can be used to manufacture various products. In some examples, the mold 100 can be configured to manufacture specific components for a vehicle, such as a cushion for a seat of the vehicle. However, the mold 100 is not limited to any particular application, size, structure, or configuration.

[0029] The mold 100 may include a pair of mold parts (e.g., lid and tray), referred to herein as first mold part 110 and second mold part 120, configured to releasably fit together or be coupled to provide a sealed mold cavity therebetween. The first mold part 110 and second mold part 120 may be separate from each other or secured together, for example, by one or more connections that allow relative movement of the first mold part 110 and second mold part 120. In some examples, the first mold part 110 and second mold part 120 may be secured together by one or more hinges, and the first mold part 110 and / or second mold part 120 may be configured to pivot about the hinge(s) to fit together and thereby form the mold cavity.

[0030] The first mold part 110 includes a core or body having first outer surfaces 112, first seal or parting line surfaces 114, and first inner surfaces 116. Similarly, the second mold part 120 includes a core or body having second outer surfaces 122, second seal or parting line surfaces 124, and second inner surfaces 126. While the first mold part 110 and the second mold part 120 are mated, the first inner surfaces 116 and the second inner surfaces 126 define the mold cavity and, thus, the outermost boundaries of the product formed with the mold 100. The first parting line surface 114 and the second parting line surface 124 are configured to contact each other and promote sufficient sealing of the mold cavity to prevent or reduce the likelihood of the prepolymer mixture from leaking from the mold cavity during the molding process.Although not shown, the mold 100 may include various components and / or structures that enable the manufacture of a product with the mold 100. As non-limiting examples, the mold 100 may include one or more pouring basins, injection ports, mold cavities, gates, sprues, clamps, etc.

[0031] The mold 100 includes one or more pairs of first column members 130 and second column members 140. Each of the first column members 130 protrudes from the first inner surface 116 of the first mold part 110, and each of the second column members 140 protrudes from the second inner surface 126 of the second mold part 120. The first column member(s) 130 include first sidewalls 132 and a first distal end 134, and the second column member(s) 140 include second sidewalls 142 and a second distal end 144. In the examples illustrated in the figures, the first sidewalls 132 and the second sidewalls 142 have a cylindrical or frustoconical cross-section. However, the first sidewalls 132 and the second sidewalls 142 are not limited to any particular cross-sectional structure.

[0032] Each of the pairs of first column members 130 and second column members 140 is configured to releasably engage each other at an interface therebetween while the first mold part 110 and the second mold part 120 are mated together to form the sealed mold cavity. In particular, the first distal end 134 of the first column member 130 includes a first interface feature configured to cooperate with a second interface feature of the second distal end 144 of the second column member 140 to form a seal between the first distal end 134 and the second distal end 144 while mated together. For example, the first interface feature may include a conical surface, and the second interface feature may include a recess or cavity configured to receive the conical surface therein, or vice versa.

[0033] While the first column member(s) 130 and the second column member(s) 140 are mated, the first sidewalls 132 and the second sidewalls 142 are exposed within the mold cavity, and their adjacent surfaces may, optionally, be substantially flush. As the mold cavity is filled with the product material and solidified to form the product therefrom, the first sidewalls 132 and the second sidewalls 142 act as barriers to define the boundaries of the passageways (e.g., through-holes) within the product. In some examples, the interfaces between the first column member(s) 130 and the second column member(s) 140 are sufficiently sealed so that spalling of the product material during the molding process is prevented or significantly reduced.

[0034] The mold 100 may be constructed from various materials, including certain polymeric, metallic, ceramic, and composite materials. In some examples, the mold 100 may be formed from steel, aluminum, or an aluminum alloy. The mold cavity defined by the first inner surfaces 116 and the second inner surfaces 126 may have various shapes and sizes. Likewise, the first column member 130 and the second column member 140 may have various shapes and sizes. In various examples, the first column member 130 and the second column member 140 in combination may have an overall longitudinal dimension (e.g., from the first inner surface 116 to the second inner surface 126) of ten millimeters or less, such as eight millimeters or less, such as six millimeters or less, when mated with the gasket therebetween.In some examples, the first column member 130 and the second column member 140 may have different longitudinal dimensions. In some examples, the first column member 130 has a longitudinal dimension that is greater than a longitudinal dimension of the second column member 140.

[0035] Fig. 2 to 4 show various non-limiting examples of pairs of the first column element 130 and the second column element 140. It should be noted that these examples are merely illustrative and the shape 100 of Fig. 1 may have other configurations, including various combinations of the Fig. 2-4 shown components and / or structures.

[0036] For the sake of simplicity, the Fig. 1 to 4, uniform reference numbers are used to identify the same or functionally related / equivalent elements, but a numerical prefix (1, 2, or 3, etc.) is added to distinguish the respective example from other examples in the figures. Given the similarities between the examples, the following discussion of the Fig. 2 to 4 primarily refer to those aspects of the examples which differ from the other examples in a notable or significant manner. Other aspects of the examples which are not further discussed may be substantially the same in terms of structure, function, materials, etc. as they are for one or more of the other examples, including the example of Fig. 1, were described.

[0037] In Fig. 2, a first column member 230 is shown having an opening at its first distal end 234 that provides access to a cavity defined by first tapered or beveled partition walls 236 and a first recessed wall 238. A second column member 240 is provided having a second distal end 244 with second tapered or beveled partition walls 246 and a second projecting wall 248. In some examples, the first beveled partition walls 236 and the second beveled partition walls 246 may extend completely around the peripheries of the first distal end 234 and the second distal end 244, respectively. In some examples, the first beveled partition walls 236 and the second beveled partition walls 246 may be radially symmetric (e.g., annular).In some examples, where the first tapered parting line walls 236 and the second tapered parting line walls 246 are radially symmetric, the first recessed wall 238 and the second protruding wall 248 may be defined by the symmetrical shape of the first tapered parting line walls 236 and the second tapered parting line walls 246 (e.g., circular, square, etc.). Although not shown, the first tapered parting line walls 236 and the second tapered parting line walls 246 are configured to contact each other or be sufficiently close to form a seal between the first column member 230 and the second column member 240 when mated.

[0038] In some examples, one or more sealing elements may be disposed at the first distal end 234 of the first column member 230 and / or the second distal end 244 of the second column member 240. The sealing element(s) may promote a leak-free seal while the first column member 230 and the second column member 240 are mated, and / or may provide a protective function for the first column member 230 and the second column member 240 to reduce wear thereof. In the example of Fig. 2, the first column member 230 includes a first sealing member 250 disposed at the first distal end 234, and the second column member 240 includes a second sealing member 260 disposed at the second distal end 244. In some examples, the first sealing member 250 may cover the entire first distal end 234. In some examples, the second sealing member 260 may cover the entire second distal end 244. The first sealing member 250 and the second sealing member 260 may be made of the same or different materials. Non-limiting materials for the sealing member(s) may include certain epoxy materials or silicone materials.

[0039] Referring to Fig. 3, a first column member 330 and a second column member 340 are provided, which have substantially the same structure as described with reference to the example of Fig. 2, i.e., a first distal end 334 includes an opening that provides access to a cavity defined by first tapered partition walls 336 and a first recessed wall 338, and a second distal end 344 includes second tapered partition walls 346 and a second projecting wall 348. The first tapered partition walls 336 and the second tapered partition walls 346 are configured to contact one another or be sufficiently close to form a seal between the first column member 330 and the second column member 340.

[0040] In this example, the first column member 330 includes a first sealing member 350 disposed at the first distal end 334, and the second column member 340 includes a second sealing member 360 disposed on the second inclined partition walls 346 and a third sealing member 362 disposed on the second projecting wall 348 of the second distal end 344. The second sealing member 360 and the third sealing member 362 are made of different materials. The first sealing member 350 may be made of the same material as the second sealing member 360 or the third sealing member 362, or a different material. In this configuration, the second sealing member 360 and the third sealing member 362 may enable different functions.For example, the second sealing member 360 may be primarily configured to promote a leak-free seal, and the third sealing member 370 may be primarily configured to enable the first column member 330 and the second column member 340 to have increased wear resistance, for example, by providing damping.

[0041] In Fig. 4, a first column member 430 is shown having a first distal end 434 with a pair of projections, each comprising first tapered partition walls 436 and a first projecting wall 438. A second column member 440 is provided having a second distal end 444 with a pair of recesses, each defined by second tapered partition walls 446 and a second recessed wall 448. The projections and recesses are configured in pairs to contact the respective first tapered partition walls 436 and the second tapered partition walls 446 or to be sufficiently close to each other to form a seal between the first column member 430 and the second column member 440 when mated.

[0042] In this example, the first column member 430 includes a first sealing member 450 disposed at the first distal end 434, and the second column member 440 includes a second sealing member 460 disposed at the second distal end 444. The first sealing member 450 and the second sealing member 460 may be made of the same or different materials.

[0043] With reference to Fig. 5 and with continued reference to Fig. 1 to 4, a flowchart shows a method 500 for manufacturing a product from a molding process, such as is carried out with the mold 100 according to an example. As can be seen from the description, the order of the method 500 is not limited to the Fig. 5, but may be executed in one or more varying orders as appropriate to the present description.

[0044] In one example, method 500 may begin at 510. At 512, method 500 may include coupling or mating a first mold part and a second mold part of a mold to enable a sealed mold cavity therebetween. The mold cavity may be defined by a first wall of the first mold part and a second wall of the second mold part. Coupling the first mold part and the second mold part results in mating a first column member protruding from the first wall and a second column member protruding from the second wall. A first distal end of the first column member is received within a cavity in a second distal end of the second column member, and a seal is formed between the first distal end and the second distal end.

[0045] At 514, method 500 may include introducing a product material into the mold cavity while the first mold part and the second mold part are mated and compacted. Various methods may be used to introduce the product material into the mold cavity, such as pouring. In some examples, the product material may be introduced into the mold cavity in a manner that causes the product material to expand (i.e., have high porosity).

[0046] At 516, method 500 may include solidifying the product material within the mold cavity to form a product. An external shape of the product may be defined by the first wall and the second wall. The first sidewalls of the first column member and the second sidewalls of the second column member define a passageway in the product. In some examples, the product may be comprised of a foam. In some examples, the passageway may be a vent.

[0047] The procedure 500 can end at 518.

[0048] The molds and methods shown herein offer several advantages over certain existing molds and methods. For example, providing a seal between the first column member and the second column member can prevent or reduce spalling during solidification of the product material, thereby promoting proper functionality of the product and / or reducing post-solidification processing steps to eliminate such spalling.

[0049] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be appreciated that the exemplary embodiment or embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the description in any way. Rather, the foregoing detailed description is intended to provide those skilled in the art with a convenient guide for implementing the exemplary embodiment or embodiments. It should be understood that various changes in the function and arrangement of elements may be made without departing from the scope of the description as set forth in the appended claims and their legal equivalents.

Claims

[1] Form which includes: a first molded part having a first wall with a first column member projecting from the first wall, the first column member having first side walls and a first distal end; and a second molded part having a second wall with a second column member projecting from the second wall, the second column member having second side walls and a second distal end having an opening to a cavity defined by inner walls of the second column member; wherein the first mold part and the second mold part are configured to releasably mate with the first wall and the second wall defining a mold cavity therebetween, wherein the first column member and the second column member are configured to releasably mate with each other while the first mold part and the second mold part mate such that the first distal end of the first column member is at least partially received within the cavity of the second distal end of the second column member and a seal is formed between the first distal end and the second distal end, wherein the mold cavity is configured to receive a product material therein and form a product therefrom, and wherein the first side walls and the second side walls are configured to define a passageway in the product. [2] The mold of claim 1, wherein the first distal end of the first column member has first tapered parting line surfaces terminating with a protruding surface, the second distal end of the second column member has second tapered parting line surfaces terminating with a depressed surface, and the first tapered parting line surfaces and the second tapered parting line surfaces are configured to mate together to form the seal between the first distal end and the second distal end. [3] The mold of claim 1, wherein the first distal end has more than one protrusion and the second distal end has more than one recess, and each of the more than one recesses is configured to receive a corresponding one of the more than one protrusions. [4] The mold of claim 1, wherein the first column member is a first of more than one first column member of the first mold part projecting from the first wall, and the second column member is a first of more than one second column member of the second mold part projecting from the second wall. [5] The mold of claim 1, further comprising a sealing member on at least one of the first distal end and the second distal end configured to assist in sealing between the first column member and the second column member while the first column member and the second column member are mated together, wherein the sealing member comprises an epoxy material or a silicone material. [6] Procedure comprising: Coupling a first mold part and a second mold part of a mold to provide a sealed mold cavity therebetween, the mold cavity defined by a first wall of the first mold part and a second wall of the second mold part, wherein the coupling of the first mold part and the second mold part causes a first column member protruding from the first wall and a second column member protruding from the second wall to mate, a first distal end of the first column member being received within a cavity in a second distal end of the second column member, and a seal being formed between the first distal end and the second distal end; Introducing a product material into the mold cavity; and Consolidating the product material to form a product, wherein first side walls of the first column member and second side walls of the second column member define a passageway in the product. [7] The method of claim 6, wherein the first distal end of the first column member has first tapered parting line surfaces terminating with a protruding surface, the second distal end of the second column member has second tapered parting line surfaces terminating with a depressed surface, and coupling the first column member and the second column member comprises mating the first tapered parting line surfaces and the second tapered parting line surfaces to form the seal between the first distal end and the second distal end. [8] The method of claim 6, wherein the first distal end has more than one protrusion and the second distal end has more than one recess, and the method comprises mating each of the first distal end and the second distal end by locating each of the more than one protrusion with a corresponding one of the more than one recesses. [9] The method of claim 6, wherein the first column member is a first of more than one first column member of the first molding that protrudes from the first wall, the second column member is a first of more than one second column member of the second molding that protrudes from the second wall, and the method comprises coupling pairs of the more than one first column member and the more than one second column member. [10] The method of claim 6, wherein the mold includes a sealing member at at least one of the first distal end and the second distal end, and the method includes mating the first column member and the second column member such that the sealing member assists in sealing between the first column member and the second column member or reduces the likelihood of wear on the first column member and the second column member.

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